Multilayer barrier materials with PVD or plasma coating for vacuum insulated structure

ABSTRACT

A method of forming a vacuum insulated structure includes providing a multi-layer sheet of material comprising at least one layer of barrier material that is disposed between first and second outer layers. The barrier material and the first and second outer layers comprise thermoplastic polymers. The multi-layer sheet of material is thermoformed to form a non-planar first component. The first component is at least partially coated utilizing a plasma polymerization process or a physical vapor deposition process to improve the barrier properties of the first component. The method further includes securing a second component to the first component to form an interior space therebetween. Porous filler material is positioned in the interior space, and a vacuum is formed in the interior space.

CROSS-REFERENCE TO RELATED APPLICATION

This application is related to U.S. patent application Ser. No. 14/980,778 filed on Dec. 28, 2015, entitled “MULTI-LAYER GAS BARRIER MATERIALS FOR VACUUM INSULATED STRUCTURE,” now U.S. Pat. No. 10,018,406, issued on Jul. 10, 2018, the disclosure of which is hereby incorporated herein by reference in its entirety.

BACKGROUND OF THE INVENTION

Various types of vacuum panels and other vacuum insulated structures have been developed for use in refrigerator cabinets, doors, cooking cavity, dryer systems, water heaters, freezers, insulation box and pipes systems, and other such components. Vacuum insulated structures may have superior insulation properties relative to conventional polyurethane foam insulation. However, known vacuum insulated structures and processes for fabricating such structures may suffer from various drawbacks.

SUMMARY OF THE INVENTION

A method of forming a vacuum insulated cabinet structure includes providing a multi-layer sheet of material comprising at least one layer of barrier material that is disposed between first and second outer layers. The barrier material and the first and second outer layers comprise thermoplastic polymers or other elastomeric or hybrid material systems. The multi-layer sheet of material is thermoformed to form a non-planar first component. The multi-layer sheet may optionally comprise a central portion and four sidewalls extending transversely from the central portion. After the multi-layer sheet of material is thermoformed or vacuum formed, at least one of the first and second outer layers is at least partially coated with a barrier material utilizing a plasma polymerization process or a physical vapor deposition process. The method further includes securing a second component to the first component to form an interior space therebetween. The second component may optionally comprise a central portion and four sidewalls extending transversely from the central portion. Porous filler material is positioned in the interior space, and a vacuum is formed in the interior space by removing the gaseous components and moisture. The first and second components are sealed together to form a vacuum insulated refrigerator cabinet structure.

These and other features, advantages, and objects of the present disclosure will be further understood and appreciated by those skilled in the art by reference to the following specification, claims, and appended drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is an isometric view of a refrigerator;

FIG. 2 is an exploded isometric view of a vacuum insulated cabinet structure for a refrigerator;

FIG. 3 is an exploded isometric view of a vacuum insulated door structure for a refrigerator;

FIG. 4 is partially schematic cross sectional view of a multilayer material that may be utilized to form wrappers, liners, and other such components of refrigerator cabinets, doors, and the like;

FIG. 5 is a partially schematic exploded cross sectional view of a three-layer sheet of material;

FIG. 6 is a partially schematic exploded cross sectional view of a four-layer sheet of material;

FIG. 7 is a partially schematic cross sectional view of a multi-layer barrier structure that has been at least partially coated with a barrier material;

FIG. 8 is a schematic view of a thermoforming tool/process; and

FIG. 9 is a schematic view of a thermoforming tool/process.

DETAILED DESCRIPTION

For purposes of description herein, the terms “upper,” “lower,” “right,” “left,” “rear,” “front,” “vertical,” “horizontal,” and derivatives thereof shall relate to the device as oriented in FIG. 1. However, it is to be understood that the disclosed subject matter may assume various alternative orientations and step sequences, except where expressly specified to the contrary. It is also to be understood that the specific devices and processes illustrated in the attached drawings, and described in the following specification, are simply exemplary embodiments of the inventive concepts defined in the appended claims. Hence, specific dimensions and other physical characteristics relating to the embodiments disclosed herein are not to be considered as limiting, unless the claims expressly state otherwise.

With reference to FIG. 1, a refrigerator 1 includes an insulated cabinet 2 having an upper fresh food compartment 6 that can be accessed through access opening 7 by opening doors 4A and 4B. The insulated refrigerator cabinet 2 also includes an insulated freezer compartment 8 that can be accessed through access opening 9 by opening a lower door/drawer 4C. Refrigerator 1 may include a cooling system (not shown) disposed in a machine compartment 10. The cooling system may include a compressor, condenser, evaporator, and other related components that are generally known in the art. Alternatively, the cooling system may comprise one or more thermoelectric elements. Door 4A may include an ice/water dispenser 16.

With further reference to FIG. 2, refrigerator cabinet 2 may comprise a wrapper 18 and a liner 20 that fits inside the wrapper 18 when assembled. An optional trim piece 22 may be utilized to interconnect and seal off front edges 24 and 26 of wrapper 18 and liner 20, respectively, when cabinet 2 is assembled. As discussed in more detail below, wrapper 18, liner 20, and/or trim piece 22 may be formed from a multilayer thermoplastic polymer material including one or more barrier layers that are substantially impervious to nitrogen, oxygen, water vapor, carbon dioxide, and other such gasses whereby a vacuum can be maintained in an internal space between wrapper 18 and liner 20. The trim piece may optionally comprise a thermoset material with or without fillers or reinforcements (i.e. fibers) and may optionally include a barrier coating. As discussed below, wrapper 18 and/or liner 20 may be fabricated by thermoforming a multi-layer sheet of thermoplastic polymer material, followed by high barrier coating at least a portion of the thermoformed material utilizing a Physical Vapor Deposition (PVD) process or a plasma polymerization coating process.

One or more of the components 18, 20 and 22 may optionally be made from metal or other suitable material. For example, wrapper 18 may be made from sheet metal, and liner 20 may be made from a multi-layer thermoformed polymer material having barrier properties. Wrapper 18 may include a generally planar central sidewall portion 17, and four sidewalls 19A-19D that extend transversely from the central sidewall portion 17 to define an interior space 15 that receives liner 20 when assembled. Liner 20 may include a generally planar rectangular central sidewall 21 that is spaced from central sidewall 17 of wrapper 18 when assembled. The liner 20 also includes sidewalls 23A-23D that extend transversely from the central sidewall 21. When assembled, the sidewalls 23A-23D are spaced inwardly from the sidewalls 19A-19D, respectively, of wrapper 18 to form a gap or space therebetween that may be filled with a porous filler material and evacuated to form a vacuum.

With further reference to FIG. 3, a refrigerator door 4A-4C may include an outer panel member 18A, and an inner liner 20A. The outer panel member 18A and liner 20A may be formed from a multilayer thermoformed polymer material having barrier properties as discussed below to thereby permit forming a vacuum between outer member 18A and liner 20A when assembled. The outer door member 18A may, alternatively, be formed from sheet metal or other material. Outer member 18A may include flanges 32A-32D that fit over and overlap corresponding flanges 34A-34B of liner 20A when assembled. The liner 20A may optionally include one or more raised ribs 28A-28C and shelves 30 as may be required for a particular application.

With reference to FIG. 4, a vacuum insulated refrigerator structure 40 includes a multi-layer polymer wrapper 42 and a multi-layer polymer liner 44. Wrapper 42 and/or liner 44 may comprise thermoformed tri-layer polymer material 60 (FIG. 5) or thermoformed quad-layer polymer material 70 (FIG. 6). Vacuum insulated structure 40 may comprise a vacuum insulated cabinet structure 2, a vacuum insulated door 4A-4C, or other vacuum insulated refrigerator structure. Polymer wrapper 42 may include flanges 46 that overlap flanges 48 of polymer liner 44. The flanges 46 and 48 may be interconnected to form an airtight seal. Alternatively, the polymer wrapper 42 and polymer liner 44 may be interconnected utilizing other suitable connecting structures and techniques such as welding, adhesive joining or compressed gasket fitting. The polymer wrapper 42 and polymer liner 44 form an interior space 50 that may be filled nano or micro porous super insulation material such as fumed silica, precipitated silica, hollow glass microsphere, perlite, rice husk ash, ceno sphere or fly ash 52, and the interior space 50 may be evacuated and sealed whereby the interior space 50 defines a vacuum. During fabrication, the polymer wrapper 42 and polymer liner 44 may be assembled together and sealingly interconnected. The wrapper and liner 42 and 44 may then be placed in a vacuum chamber, and silica powder 52 may be introduced into the interior space 50 through one or more openings 54. The openings 54 may then be sealed with a cap 56, and the vacuum insulated refrigerator structure 40 may then be removed from the vacuum chamber.

As discussed in more detail below in connection with FIG. 7, the multi-layer polymer wrapper and/or the multi-layer polymer liner 44 may be coated after thermoforming utilizing plasma polymerization or Physical Vapor Deposition (PVD) processes or other suitable spray process. These coating processes further enhance the barrier properties by blocking oxygen, nitrogen, water vapor, and other gasses.

With further reference to FIG. 5, the wrapper 42 and/or liner 44 may be thermoformed from a tri-layer sheet 60 of polymer material. The sheet 60 comprises first and second outer structure layers 62 and 64 and a barrier layer 66 that is disposed between the first and second outer layers 62 and 64, respectively. The layers 62, 64, and 66 comprise thermoplastic polymers. Layer 66 may optionally comprise an elastomeric material. Layers 62, 64, and 66 are shown in a spaced apart exploded view in FIG. 5. However, it will be understood that the layers 62, 64, and 66 are coextruded or laminated together to form a single multi-layer sheet prior to thermoforming. The first and second outer structural layers 62 and 64, respectively, may comprise a suitable thermoplastic polymer material such as High Impact Polystyrene (HIPS) or Acrylonitrile, Butadiene and Styrene (ABS), Polypropylene or Poly Butylene Teraphthalate or Polyethylene. The barrier layer 66 may comprise a thermoplastic polymer material that is impervious to one or more gasses such as nitrogen, oxygen, water vapor, carbon dioxide, etc. such that the wrapper and liner 42 and 44 (FIG. 4) provide a barrier to permit forming a vacuum in interior space 50. The barrier layer 66 preferably comprises a material that blocks both oxygen and water vapor simultaneously. Examples of such material include Polyvinylidene Chloride (PVdC), high barrier nylon, or liquid crystal polymer. The layers 62, 64, and 66 may be co-extruded or laminated together. The thickness of the barrier layer 66 may be adjusted as required for different applications to meet varied requirements with respect to oxygen and water vapor transmission rates. The materials of layers 62, 64, and 66 are selected to have very good thermoforming properties to permit deep draw ratio thermoforming of components such as wrapper 18 and liner 20 (FIG. 2) and the door components 18A and 20A (FIG. 3), and other vacuum insulated refrigerator structures. Typically, the first outer layer 62 and the second outer layer 64 have a thickness of about 0.1 mm to 10 mm, and the barrier layer(s) have a thickness of about 0.1 mm to 10 mm.

The following are examples of material combinations that may be utilized to form tri-layer sheet 60:

Example 1: HIPS/PVdC/HIPS

Example 2: HIPS/Nylon/HIPS

Example 3: HIPS/MXD-6 Nylon/HIPS

Example 4: HIPS/MXD-6 Nylon with clay filler/HIPS

Example 5: HIPS/Liquid Crystal Polymer/HIPS

With further reference to FIG. 6, a quad-layer sheet 70 having first and second outer layers 72 and 74, respectively, and two barrier layers 76 and 78 may also be utilized to form wrapper 18, liner 20 (FIG. 2) and outer member 18A and inner member 20A (FIG. 3) to form vacuum insulated refrigerator cabinet structures, vacuum insulated doors, or other such components. The outer layers 72 and 74 may comprise HIPS, ABS, or other suitable polymer material (Polypropylene or Poly Butylene Teraphthalate or Polyethylene that is capable of being thermoformed. The first barrier layer 76 may comprise a thermoplastic polymer material that is substantially impervious to water vapor. Examples of thermoplastic polymer or elastomeric materials for first barrier layer 76 include fluoropolymer such as Tetrafluoroethylene (THV), polychlorotrifluoroethylene (PCTFE), Cyclic Olefin Copolymer (COC), Cyclic Olefin Polymer (COP) or high density polyethylene (HDPE). The second barrier layer 78 may comprise a thermoplastic polymer that is substantially impervious to oxygen. Examples of thermoplastic polymer materials include ethylene vinyl alcohol EVOH. An optional tying layer 80 comprising a thermoplastic polymer material may be disposed between the barrier layers 76 and 78. Tie layer 80 may be utilized to bond barrier layers 76 and 78 to one another. Examples of suitable materials for the tie layer include adhesive resins, such as modified polyolefin with functional groups that are capable of bonding to a variety of polymers and metals.

The following are examples of material combinations that may be utilized to form quad-layer sheet 70:

Example 1: HIPS/EVOH/HDPE/HIPS

Example 2: HIPS/EVOH/COP/HIPS

Example 3: HIPS/EVOH/COC/HIPS

Example 4: HIPS/EVOH/THV/HIPS THV

Example 5: HIPS/EVOH/PCTFE/HIPS

Layers 72, 74, 76, 78 and 80 are coextruded or laminated together to form a single sheet of material prior to thermoforming.

It will be understood that wrappers, liners, and other such components as disclosed herein are not limited to the tri-layer sheet 60 or the quad-layer sheet 70 configurations described above, and additional layers of material may also be utilized.

With further reference to FIG. 7, after the multi-layer sheet 60 or 70 is thermoformed, the sheet 60 or 70 may be at least partially coated with a layer of material 82. Layer 82 may comprise an organic or inorganic material such as silicon oxide that is deposited utilizing a plasma polymerization process. Alternatively, layer 82 may comprise a metallic layer such as aluminum, stainless steel, chrome, nickel or other suitable metal that is applied utilizing a Physical Vapor Deposition (PVD) process. Accordingly, layer 82 preferably comprises a barrier material that provides additional barrier performance and blocks gasses to maintain the vacuum formed in interior space 50 (FIG. 4). An additional outer layer in the form of a protective cap 84 may be applied over the coating 82. The protective cap layer may comprise a organic or inorganic material having a thickness of about 10 to 150 microns. The protective cap 84 may be applied by spray, PVD or a plasma process. The protective cap 84 improves the robustness/wear characteristics of the surface of a liner, wrapper, or other component. The layer 82 and cap 84 may be applied to a wrapper or liner after thermoforming, preferably (optionally) prior to interconnecting the wrapper and liner (e.g. wrapper 42 and liner 44; FIG. 4). Alternatively, the layer 82 and protective cap 84 may be applied after the wrapper and liner are assembled and sealed together. However, the coating layer 82 and the cap 84 are preferably applied prior to assembly of the wrapper and liner to thereby permit both the inner and outer sides of the wrapper and liner to be coated with layer 82 and cap 84.

With further reference to FIGS. 8 and 9, multi-layer sheets 60 and 70 may be thermoformed utilizing male and female mold parts 86 and 88, respectively. Sheet 60 or 70 is initially positioned between mold parts 86 and 88 as shown in FIG. 8, and the sheet 60 or 70 is heated to temperature at which the sheet 60 or 70 can be plastically deformed by pressing the mold parts together as shown in FIG. 9 to form a wrapper, liner, or other such component. As used herein, the term “thermoforming” and variations thereof broadly means a forming process in which a sheet of thermoplastic polymer material is heated and formed, and “thermoforming” is not limited to the specific process/tools shown in FIGS. 8 and 9. For example, components may be thermoformed utilizing a vacuum forming process whereby a vacuum is utilized to deform sheet 60 or 70 to fit closely in female mold 87 such that a male mold part 86 is not required.

It is to be understood that variations and modifications can be made on the aforementioned structure without departing from the concepts of the present disclosure, and further it is to be understood that such concepts are intended to be covered by the following claims unless these claims by their language expressly state otherwise. 

The invention claimed is:
 1. A method of forming a vacuum insulated appliance structure, the method comprising: providing a multi-layer sheet of material comprising at least one layer of inner barrier material disposed between first and second outer layers, wherein the inner barrier material and the first and second outer layers comprise thermoplastic polymers having thermoforming properties that permit deep draw ratio thermoforming; heating and plastically forming the sheet of material to form a first component, at least a portion of which is non-planar; followed by at least partially coating at least one of the first and second outer layers with an outer barrier material utilizing a plasma polymerization process or a physical vapor deposition process; securing a second component to the first component to form an interior space therebetween; positioning porous filler material in the interior space; forming a vacuum in the interior space; and sealing the first and second components together around the porous filler material to form a vacuum insulated appliance structure.
 2. The method of claim 1, wherein: the outer barrier material comprises an inorganic material.
 3. The method of claim 2, wherein: the outer barrier material comprises metal.
 4. The method of claim 1, including: applying a protective cap over the outer barrier material.
 5. The method of claim 4, wherein: the protective cap is about 10-150 microns thick.
 6. The method of claim 4, wherein: the protective cap is formed by spray, PVD or plasma process.
 7. The method of claim 1, wherein: the first component comprises a central portion and four sidewalls extending transversely from the central portion; the second component comprises a central portion and four sidewalls extending transversely from the central portion.
 8. The method of claim 1, wherein: the first component comprises a door liner; the second component comprises a door wrapper.
 9. The method of claim 1, wherein: the outer layers comprise at least one of HIPS or ABS, PP, PBT or PE.
 10. The method of claim 9, wherein: the inner barrier material comprises at least one of PVDC, nylon, or liquid crystal polymer.
 11. The method of claim 10, wherein: the at least one layer of inner barrier material comprises first and second inner barrier layers.
 12. The method of claim 11, wherein: the first inner barrier layer comprises at least one of a fluoropolymer, COC, COP, or HDPE.
 13. The method of claim 12, wherein: the second inner barrier layer comprises EVOH.
 14. The method of claim 11, including: a tie layer disposed between the first and second inner barrier layers, wherein the tie layer comprises a tying polymer material that bonds to the first and second inner barrier materials.
 15. The method of claim 14, wherein: the tying polymer material comprises modified polyolefin with functional groups whereby the tying polymer is capable of bonding to polymers and metals.
 16. The method of claim 7, wherein: the first component comprises a liner of a refrigerator cabinet; the second component comprises a sheet metal wrapper of a refrigerator cabinet.
 17. The method of claim 1, wherein: heating and forming the sheet of material comprises a thermoforming process.
 18. The method of claim 1, wherein: comprising first and second inner barrier materials, respectively, wherein the first inner barrier material is impervious to oxygen.
 19. A method of forming a vacuum insulated appliance structure, the method comprising: providing a multi-layer sheet of material comprising at least one layer of inner barrier material disposed between first and second outer layers, wherein the inner barrier material and the first and second outer layers comprise thermoplastic polymers; heating and forming the sheet of material to form a first component, at least a portion of which is non-planar; followed by at least partially coating at least one of the first and second outer layers with a metal outer barrier material utilizing a plasma polymerization process or a physical vapor deposition process; securing a second component to the first component to form an interior space therebetween; positioning porous filler material in the interior space; forming a vacuum in the interior space; and sealing the first and second components together around the porous filler material to form a vacuum insulated appliance structure. 